Welding and straightening operations are not permitted on load-bearing or wheelcontrolling

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Millicent Haynes
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1 Page 1 of 9 Volkswagen > Passat > Suspension, Wheels, Steering 40 - Front Suspension. Note: If a vehicle that has a drive axle removed is to be moved, an outer CV joint must be installed in place of the drive axle and be tightened to 50 Nm. Otherwise, the wheel bearing will be damaged. Welding and straightening operations are not permitted on load-bearing or wheelcontrolling components. Always replace self-locking nuts. Always replaced corroded bolts/nuts. Spring, Removing and Installing Front Wheel Bearing, Removing and Installing Front Wheel Bearing, Wheel Bearing Housing Installed, Removing and Installing Stabilizer Mountings, Replacing Subframe Mountings, Replacing

Page 2 of 9 1 - Hex bolt, 75 Nm 2 - Washer 3 - Hex bolt Vehicles with steel mounting bracket; bolt length: M10 x 60 Vehicles with aluminum

2 Page 2 of Hex bolt, 75 Nm 2 - Washer 3 - Hex bolt Vehicles with steel mounting bracket; bolt length: M10 x 60 Vehicles with aluminum mounting bracket; bolt length: M10 x Upper rear control arm Front and Rear Upper Control Arm Bushings, Replacing 5 - Hex bolt, 7 Nm

3 Page 3 of Bolt 7 - Self-locking hex nut, 50 Nm 8 - Hex bolt M10 x 100 Press out of wheel bearing housing Wheel Bearing Housing, Separating Connections Between Upper Control Arms and 9 - Self-locking hex nut, 40 Nm 10 - Upper front control arm Can only be removed with mounting bracket Mounting bracket, removing and installing Mounting Bracket, Removing and Installing Mount, replacing Front and Rear Upper Control Arm Bushings, Replacing 11 - Suspension strut Allocation of coil spring to vehicle 12 - Hex bolt M12 x 1.5 x Guide link Lower Control Arm, Removing and Installing and Guide Link, Removing and Installing If hydraulic mount is leaking, it must be replaced Guide Link Mountings, Replacing 14 - Self-locking nut Application See Parts Catalog

4 Page 4 of 9 Flange nut, M12 x 1.5, for wheel bearing housing without bushing (old design) Bearing Housing/Tie Rod End, Modified Wheel Tightening torque: 100 Nm Combination nut, M12 x 1.5, for wheel bearing housing with bushing (new design) Wheel Bearing Housing/Tie Rod End, Modified Tightening torque: 125 Nm Flange nuts should be installed on vehicles with wheel bearing housings without bushings and support arms of old design. When installing wheel bearing housings with bushings, flange nuts must be replaced with combination nuts 15 - Wheel bearing housing Application See Parts Catalog Different wheel bearing housing designs (with and without bushings) Housing, from MY 2002, Modified Wheel Bearing Wheel Bearing Housing, Removing and Installing Modification Wheel Bearing Housing/Tie Rod End, Modified 16 - Shield plate 17 - Hex bolt Changed from hex socket bolt 18 - Socket hex head bolt, 10 Nm 19 - Self-locking nut Application See Parts Catalog Flange nut, M12 x 1.5, for wheel bearing housing without bushing (old design) Bearing Housing, from MY 2002, Modified Wheel Tightening torque: 100 Nm Combination nut, M12 x 1.5, for wheel bearing housing with bushing (new design)

5 Page 5 of 9 Wheel Bearing Housing, from MY 2002, Modified Tightening torque: 125 Nm Flange nuts should be installed on vehicles with wheel bearing housings without bushings and support arms of old design. When installing wheel bearing housings with bushings, flange nuts must be replaced with combination nuts Hex bolt M12 x 1.5 x Self-locking hex nut, 90 Nm Tighten nuts in unloaded condition Front Axle, Lifting to Unloaded Position! 22 - Connecting link Arrow on connecting link points in driving direction Modification Stabilizer Connecting Link, Modified 23 - Self-locking nut 40 Nm plus an additional 90 degree 1 / 4 Depending upon design, use self-locking nut or nut with ribs on the underside 24 - Hex bolt M12 x 1.5 x Lower control arm Application See Parts Catalog Different lower control arm designs (for wheel bearing housings with and without bushings) Control Arm, from MY 2002, Modified Checking Lower Control Arm, Checking

6 Page 6 of 9 Lower Control Arm, Removing and Installing Mount, replacing Control Arm Mountings, Replacing 26 - Clip 27 - Hex bolt, 75 Nm M10 x 70 If weld nut threads are damaged, threads can be repaired using Heli-Coil thread inserts. Servicing thread in side rail Longitudinal Member Threads, Servicing 28 - Hex bolt M12 x 1.5 x Nm plus an additional 90 degree 1 / 4 If weld nut threads are damaged, threads can be repaired using Heli-Coil thread inserts. Servicing thread in side rail Longitudinal Member Threads, Servicing 29 - Subframe/engine carrier Subframe, Removing and Installing 30 - Self-locking nut 40 Nm plus an additional 90 degree 1 / 4 Modification Stabilizer Connecting Link, Modified 31 - Hex bolt M8 x 25 Was modified Modified bolts for subframe supports

7 Page 7 of 9 If weld nut threads are damaged, threads can be repaired using Heli-Coil thread inserts. Servicing thread in side rail Longitudinal Member Threads, Servicing 32 - Subframe support 33 - Self-locking nut 80 Nm plus an additional 90 degree 1 / 4 Tighten nuts in unloaded condition Front Axle, Lifting to Unloaded Position! 34 - Self-locking nut 80 Nm plus an additional 90 degree 1 / 4 Tighten nuts in unloaded condition Front Axle, Lifting to Unloaded Position! 35 - Multi-point socket head bolt 36 - Backing plate 37 - Drive axle 38 - Drive axle with triple roller joint 39 - Socket head bolt 40 - Hex bolt Note: Vehicles with steel mounting bracket; bolt length M10 x 60 Vehicles with aluminum mounting bracket; bolt length M10 x Mounting bracket Material was revised from steel to aluminum.

8 Page 8 of 9 Installing different mounting brackets is not permitted. Mounting Bracket, Removing and Installing 42 - Self-locking nut 50 Nm plus an additional 90 degree 1 / 4 Tighten nuts in unloaded condition Front Axle, Lifting to Unloaded Position! 43 - Self-locking hex nut, 22 Nm. Modified bolts for subframe supports The subframe support bolts were changed three times since start of production. Bolt - A - was used at start of production. Bolt - A - has no ribs on the underside of the washer, it is smooth. Then the bolt was changed to bolt - B -. Ribbed bolt - B - is ribbed on the underside - arrow -. As of 04.99, bolt - C - has been put into use. It can be installed in all vehicles. Bolt - C - is ribbed on the underside of the bolt head and washer.

9 Page 9 of 9 The bolts have different tightening torques. Tightening torques: Hex bolt A Ribbed bolt B Ribbed bolt C 25 Nm 75 Nm 30 Nm Copyright 2008 Volkswagen of America, Inc. and Bentley Publishers. All rights reserved. Last processed:

Front suspension - Plus suspension, servicing. Volkswagen Passat B4 - Front suspension - Plus suspension, servicing

Volkswagen Passat B4 - Front suspension - Plus suspension, servicing Page 1 / 22 40-2 Front suspension - Plus suspension, servicing I - Subframe, anti-roll bar, control arm (Plus suspension), removing